Air purifying coating system and method for making same

ABSTRACT

An air purifying coating system and method for making same having a carrier agent and a diatomic frustule particle dispersion combined with the carrier agent. The diatomic frustule particle dispersion may include diatomic frustule zinc oxide particles, diatomic frustule titanium dioxide particles, or combinations thereof. The coating system may include 70-99.9 weight percent carrier agent and 0.1-30 weight percent diatomic frustule particle dispersion. The carrier agent of the coating system may include a cleaning agent or a polishing agent. The diatomic frustule particle dispersion may include 1-35 micron particle size diatomic frustule particles combined with water and dispersion additive. The dispersion may further include an anti-settling additive, a rheology additive, and/or or a defoamer.

BACKGROUND

The present invention relates generally to the field of coatings. Moreparticularly, the present invention relates to an air purifying coatingsystem having a diatomic frustule particle dispersion combined with acarrier agent, such as a cleaning and/or a polishing agent. The diatomicfrustule particle dispersion may be zinc oxide, titanium oxide, orcombinations thereof. The present invention also relates to a method ofmaking the air purifying coating system. The air purifying coatingsystem may be applied to substrates, such as wood, laminate, orsynthetic surfaces such as PVC, vinyl, linoleum, or hard surfaces suchas concrete, stone, terrazzo, granite, or marble and reduces toxins,such as volatile organic compounds (VOCs), from the surrounding airenvironment.

Indoor air quality continues to be an important area of concern. Indoorair pollutants can come from sources such as carpets, furnaces,furniture, insulation, pets, refuse, and fuels from the garage. Whilecurrent technology in home building makes houses more air tight, thiscan trap VOCs within a house and lead to situations such as sick housesyndrome.

Products are available that claim to clean VOCs from the indoor air.Many of these available products however have shortcomings. For example,many of these products become inactive as they fill with impurities andlose their VOC reduction efficacy.

Thus there is a need for easy to use products that provide lastingreductions of VOCs and toxins from indoor air environments.

SUMMARY

The following presents a simplified summary of the invention in order toprovide a basic understanding of some aspects of the invention. Thissummary is not an extensive overview of the invention. It is notintended to identify key or critical elements of the invention or todelineate the scope of the invention; its sole purpose is to presentconcepts of the invention in a simplified form as a prelude to the moredetailed description that is subsequently presented.

The present invention includes an air purifying coating system. In oneembodiment of the invention, the air purifying coating system includes acarrier agent and a diatomic frustule particle dispersion combined withthe carrier agent, wherein the dispersion may be a diatomic frustulezinc oxide particle dispersion, a diatomic frustule titanium oxideparticle dispersion, or a combination thereof. In one embodiment of thepresent invention, the coating system includes 70-99.9 weight percentcarrier agent and 0.1-15 weight percent diatomic frustule particledispersion.

In an embodiment of the air purifying coating system of the presentinvention, the diatomic frustule particle dispersion may includediatomic frustule particles having a particle size of 1-35 microns. In afurther embodiment of the present invention, the diatomic frustuleparticle dispersion may include water, diatomic frustule particles, anda dispersion additive. The diatomic frustule particle dispersion mayalso include an anti-settling additive, a rheology additive, and/or adefoamer.

In one embodiment of the present invention, the diatomic frustuleparticle dispersion includes 50-75 weight percent water, 20-50 weightpercent diatomic frustule particles, 1-10 weight percent dispersionadditive, such as a copolymer of pigment affinic groups, and 0.1-2weight percent rheology additive, such as modified urea resin.

In an embodiment of the air purifying coating system of the presentinvention, the carrier agent may be a cleaning agent. Further, thecoating system of the present invention may include 95-99.9 weightpercent cleaning agent and 0.1-5.0 weight percent diatomic frustuleparticle dispersion. In an embodiment of the air purifying coatingsystem of the present invention, the cleaning agent may include acrylicresin, surfactant, and hydrotropes. In another embodiment of the airpurifying coating system of the present invention, the cleaning agentmay include 80-97 weight percent water, 0.5-5 weight percent acrylicresin, such as alkali-soluble metal-complexed acrylic copolymer, 0.1-1weight percent hydrotrope, 0.1-3 weight percent emulsifier, such asalkyl polyethylene glycol ether made from a C10-Guerbet Alcohol andethylene oxide, 0.1-1 weight percent freeze thaw agent, such as asurfactant blend, 0.1-1 weight percent flow additive, such aspolyether-modified, hydroxy-functional polydimethylsiloxane, and/orpolyether modified siloxane, 0.1-1 weight percent defoamer, such as foamdestroying polysiloxanes, 0.1-1 weight percent polyether modifiedsiloxane surface modifier, 0.1-1 weight percent anti-settle additive,such as a modified urea resin, and 0.1-0.5 weight percent biocide, suchas a blend of benzoisothiazilinone and methylisothiazilinone. Thedispersion may be a diatomic frustule zinc oxide particle dispersion, adiatomic frustule titanium oxide particle dispersion, or a combinationthereof.

In an embodiment of the air purifying coating system of the presentinvention, the carrier agent may be a polishing agent. Further, thecoating system of the present invention may include 70-99.9 weightpercent polishing agent and 0.1-30 weight percent diatomic frustuleparticle dispersion. In an embodiment of the air purifying coatingsystem of the present invention, the polishing agent may include water,binder, freeze thaw agent, solvent, defoamer, and a surface modifier. Inone embodiment, the binder may be acrylic copolymer resin.Alternatively, the binder may also be polyurethane resin. In anotherembodiment of the air purifying coating system of the present invention,the polishing agent may include 45-95 weight percent water, 3-53 weightpercent acrylic copolymer and acrylic copolymer, 1-5 weight percentsolvent, 0.0-1 weight percent freeze thaw additive, 0.1-1 weight percentanti-settling additive, such as a modified urea resin, 0.01-1 weightpercent flow additive, such as polyether modified siloxane and/or afluorinated surfactant, 0.01-1 weight percent defoamer, 0.01-0.5 weightpercent biocide, 0.1-3 weight percent wax additive, and 0.01-0.1 weightpercent dispersant, such as a copolymer of pigment affinic groups. Thedispersion may be a diatomic frustule zinc oxide particle dispersion, adiatomic frustule titanium oxide particle dispersion, or a combinationthereof.

The present invention also includes a method of manufacturing an airpurifying coating system. In one embodiment of the invention, the methodincludes the steps of providing diatomic frustule particles, wherein theparticles are diatomic frustule zinc oxide particles, diatomic frustuletitanium oxide particles, or a combination thereof, combining thediatomic frustule particles with water and a dispersing additive to forma diatomic frustule particle dispersion, providing a carrier agent, andcombining the carrier agent and the diatomic frustule particledispersion to form the air purifying coating system of the presentinvention.

In an embodiment of the method of the present invention, the diatomicfrustule particles have a particle size of 1-35 microns. Further, themethod of the present invention may further include the step of millingthe diatomic frustule particles to a particle size of 1-35 microns. Inan embodiment of the present invention, the method may further includecombining the diatomic frustule particles with a rheology additive and adefoamer to form the dispersion. In an embodiment of the method of thepresent invention, the method may include combining 50-75 weight percentwater, 20-50 weight percent diatomic frustule particles, and 1-10 weightpercent dispersing additive to form the diatomic frustule particledispersion.

The method of the present invention may include combining 85-99.9 weightpercent carrier agent and 0.1-15 weight percent diatomic frustuleparticle dispersion. In one embodiment of the method of the presentinvention, the carrier agent may be a cleaning agent. Further, themethod may include combining 95-99.9 weight percent cleaning agent with0.1-5 weight percent diatomic frustule particle dispersion. In anotherembodiment of the method of the present invention, the carrier agent maybe a polishing agent. Further, the method may include combining 70-99.9weight percent polishing agent with 0.1-10 weight percent diatomicfrustule particle dispersion. In connection with the cleaning agent orthe polishing agent, diatomic frustule particles may be diatomicfrustule zinc oxide particles, diatomic frustule titanium oxideparticles, combinations thereof.

Further features of the present invention will be apparent from thedescription that follows. After review, such features may in part beobvious from the description or may be learned by practice of theinvention. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

The present invention relates to an air purifying coating system andmethod of making same. The air purifying coating system may be an airpurifying cleaner polishing system. For example, the air purifyingcleaner polishing system may be in the form of a cleaner and/or polishthat is applied to substrates and surfaces. When applied to a substrateor surface, the air purifying coating system preferably reduces indoorair toxins, such as volatile organic compounds. Additionally, thecoating system may also provide acceptable chemical resistance, glosslevel, scruff resistance, and/or clarity to the surface where it isapplied. The air purifying coating system of the present invention mayinclude a carrier agent such as a cleaning agent, a polishing agent, ora cleaning/polishing agent. The air purifying coating system may furtherinclude a diatomic frustule particle dispersion combined with thecarrier agent, wherein the dispersion may be a diatomic frustule zincoxide particle dispersion, a diatomic frustule titanium oxide particledispersion, or a combination thereof. The air purifying coating systemof the present invention may be combined with further components and/oradditives depending on the intended use of the coating system.

Although primarily described herein in terms of its use as a surfacecleaner and/or polish, it will be clear that the air purifying coatingsystem of the present invention may have various other uses. Further,while the air purifying coating system of the present invention isprimarily identified as providing beneficial air purifyingcharacteristics when applied to surfaces and substrates, it may alsoexhibit additional beneficial characteristics and properties.

Unless otherwise stated, the following terms used in the specificationand claims have the meanings given below.

As used herein unless otherwise stated, the term “nanoparticle” is givenits ordinary and customary meaning in the art and refers to a particleconsisting in size between 1-100 nanometers, or 1×10⁻⁹ meters.

As used herein unless otherwise stated, the term “micron” is given itsordinary and customary meaning in the art and refers to a particlehaving a size between 1-100 microns, or 1×10⁻⁶ meters.

As used herein unless otherwise stated, the term “mill” is given itsordinary and customary meaning in the art and refers to a machine usedto reduce pigment particle size to a repeatable and consistentdistribution.

As used herein unless otherwise stated, the term “surfactant” refers toan organic polymer with positive or negative charges used to stabilizeand separate pigment particles in a solution of water or organicsolvent.

As used herein unless otherwise stated, the term “dispersion solution”refers to a solution containing pigment, solvent, defoamers,surfactants, and anti-settling additives.

As used herein unless otherwise stated, the term “polymer/resin” refersto an organic compound used in paints, coatings, and polishes to bindpigments and protect surfaces such as wood, concrete, syntheticsurfaces, and natural stone.

As used herein unless otherwise stated, the term “polishing agent”refers to a coating that is used to add protection to a surface such aswood, vinyl, laminate, pvc, linoleum, stone, granite, terrazzo, marble,or concrete floor.

As used herein unless otherwise stated, the term “cleaning agent” refersto a material comprised of surfactants, solvents, water, and polymericresins.

As used herein unless otherwise stated, the term “particle sizeanalyzer” refers to a device that determines the particles size andcount in a solution. The values can be calculated in nanometers ormicrometers. The unit being utilized for testing herein is a AccusizerN3000 but other units may be used without departing from the scope ofthe invention.

As used herein unless otherwise stated, the term “weatherometer” refersto a device used to simulate sunlight exposure in a controlled andaccelerated method. The chamber can be controlled to be varioustemperatures as well as humidity conditions. The unit being utilized fortesting herein is a XE1 with an air-conditioned chamber to maintain STP(standard temperature and pressure) conditions but other units may beused without departing from the scope of the invention.

Reference now will be made in detail to embodiments and examples of thepresent invention. The particular components and amounts thereof recitedin these examples, as well as other conditions and details, should notbe construed to unduly limit this invention. Notwithstanding that thenumerical ranges and parameters setting forth the broad scope of theinvention are approximations, the numerical values set forth in thespecific examples are reported as precisely as possible. Any numericalvalue, however, inherently contains certain errors necessarily resultingfrom the standard deviation found in their respective testingmeasurements. Moreover, all ranges disclosed herein are to be understoodto encompass any and all sub-ranges subsumed therein. In the examplesand discussion throughout this description, all percentages, proportionsand ratios are by weight (mass) unless otherwise indicated.

An air purifying coating system and method of making same is disclosed.As stated above, the system may include a carrier agent such as acleaning agent, a polishing agent, or a cleaning/polishing agent, whichis combined with a diatomic frustule particle dispersion. The diatomicfrustule particle dispersion may be a diatomic frustule zinc oxideparticle dispersion, a diatomic frustule titanium oxide particledispersion, or a combination thereof. In one embodiment of the airpurifying coating system of the present invention, the coating systemmay comprise 70-99.9 weight percent carrier agent and 0.1-15.0 weightpercent diatomic frustule particle dispersion.

The diatomic frustule particle dispersion includes diatomic frustuleparticles (“DF particles”) combined with a dispersion solution. Thediatomic frustule particles may be diatomic frustule zinc oxideparticles (“DFZnO particles”), diatomic frustule titanium oxideparticles (“DFTiO₂ particles”), or a combination thereof. The DFparticles used in connection with the present invention are preferablynanoparticles. The diatomic frustule particle dispersion (“DFdispersion”) is preferably a stable aqueous dispersion for incorporationinto a carrier agent, such as cleaners, polishes, and cleaner/polishes.

Prior to forming the DF dispersion, the DF particles may be milled tomake the pigment more stable and uniform in solution. The milling may beachieved using an HCP immersion mill from Hockmeyer Corporation, and themedia may be zirconium oxide 0.4 mm in size.

A DF dispersion, may include several components to insure the pigmentparticles are evenly separated and stabilized in solution. Further, theDF dispersion may also utilize components for settling and defoaming. Inone embodiment of the DF dispersion of the present invention, thedispersion may include approximately 50-75 weight percent water. The DFdispersion may also include approximately 20-50 weight percent DFparticles, such as Diatom ix 10-micron powder or diatomic frustule zincoxide particle powder (ZnO DPA). Further, the DF dispersion may includeapproximately 1-10 weight percent dispersing additive. The DF dispersionmay also include approximately 0.1-2 weight percent rheology additive,such as a nonionic urethane copolymer. Additionally, the DF dispersionmay include approximately 0.01-0.2 weight percent of a defoamer tominimize foam generation during the mixing process.

The DF dispersion may be made by combing water with dispersing additivein a container such as a dissolver. Preferably the dispersing additiveis added to the water under moderate agitation and mixed forapproximately 5 minutes. The rheology additive may then be added undermoderate agitation for approximately 10 minutes until the rheologyadditive is mixed thoroughly. Depending on the foam generation of thedispersion, a defoamer may then be added to keep foam from generating inthe mixing process. Finally, the DF particles, such as Diatomix10-micron powder or diatomic frustule zinc oxide particle powder (ZnODPA), is preferably sifted into the batch under agitation. Thedispersion may then be transferred from the dissolver to an immersionmill, such as a HCP immersion mill. The DF dispersion may then be milleduntil the effective Hegman particle size is preferably greater than 1and less than 100 microns or more preferably greater than 6 or less than20 microns. In one embodiment, the milling speed is approximately2500-3500 rpms.

Carrier agents of the present invention, including most cleaners,polishes, and cleaner/polishes, typically have a lower viscosity and arelower non-volatile material products than the DF particles. Thus, the DFparticles are preferably placed into a dispersion form to aid inincorporating the particles into such lower viscosity and lowernon-volatile material agents.

As stated above, carrier agents of the present invention includecleaning agents. When cleaning agents are incorporated into the presentinvention, an air purifying cleaning system is formed. The cleaningagents of the present invention include both cleaners and refresherproducts and are typically water-based. Cleaning agents of the presentinvention preferably include acrylic resins and more preferably includealkali-soluble metal-complexed acrylic copolymer, which have acid valuesgreater than 25 mg KOH. Cleaning agents of the present invention alsopreferably include surfactants, such as alkyl polyethylene glycol ethermade from a C10-Guerbet Alcohol and ethylene oxide. Surfactants areoften used for cleaning, degreasing and emulsifying soils and othertypes of contaminates. In water-based cleaning systems, freeze thawstability is important to the maintenance of the systems performance.Thus, when water-based cleaning agents are incorporated in connectionwith the present invention, surfactants that provide freeze thawstability but do not interfere with system performance may beincorporated. Cleaning agents of the present invention may furtherutilize hydrotropes for solubilizing hydrophobic compounds.

To insure adequate surface wetting and surface protection of the airpurifying cleaning system, surface wetting materials that lower thesurface tension of the cleaning agent and provide a uniform layer overthe flooring material may be used. Functionalized surface wettingmaterials may also be used, which can add a level of surface marringprotection.

With the use of surfactants, defoaming agents that limit excessivefoaminess or bubbling are often incorporated into the air purifyingcleaning system of the present invention. Preferably such defoamingagents, such as foam destroying polysiloxanes, have long term efficacywithout having an adverse interaction with the surfactants. Whenincorporating the DF particles into a lower viscosity cleaning agent, arheology modifier may be used to prevent the DF particles from becominghardened on the bottom of the container.

Glycol ether solvents, such as dipropylene glycol monomethyl ether,propylene glycol butyl ether, tripropylene glycol methyl ether, and/ordiethylene glycol ethyl ether, may be incorporated into the airpurifying cleaning system to aid in solubilizing the greases and/orresins in the system.

In one embodiment of the present invention, the cleaning agent of theair purifying cleaning system includes approximately 80-97 weightpercent water. Further, the cleaning agent may include approximately0.5-5 weight percent alkali-soluble metal-complexed acrylic copolymerfor adhesion and resolubility. Additionally, the cleaning agent of thepresent invention may include approximately 0.1-1 weight percenthydrotrope, such as sodium cumene sulfonate. The cleaning agent of thepresent invention may include surfactants to address cleaning andemulsifying of dirt. In one embodiment, the cleaning agent of thepresent invention may include approximately 0.1-3 weight percentemulsifiers. For example, approximately 0.1-1 weight percent alkylpolyethylene glycol ether made from a C10-Guerbet Alcohol and ethyleneoxide may be incorporated into the cleaning agent. Specialty additivesmay also be incorporated into the cleaning agent of the air purifyingcleaning system. For example, freeze thaw additives such asapproximately 0.1-1 weight percent freeze thaw agents, such as asurfactant blend, flow additives at approximately 0.01-1 weight percent,such as foam destroying polysiloxanes, at approximately 0.1-1 weightpercent, surface modifiers at approximately 0.1-1 weight percent,anti-settle additives at approximately 0.1-1 weight percent,approximately 0.1-0.5 weight percent biocides, such as a blend ofbenzoisothiazilinone and methylisothiazilinone, and solvents for resinsolubility may be incorporated. In an embodiment of the presentinvention, approximately 0.1-5 weight percent DF dispersion may beincorporated into the cleaning agent to form the air purifying cleaningsystem of the present invention.

Polishing agents may also be used as carrier agents of the presentinvention. When polishing agents are incorporated into the presentinvention, an air purifying polishing system is formed. Polishing agentsmay be used to add protection to a surface such as a wood, synthetics,stone, and/or other hard surface. For example, polishing agents are usedto protect substrates and surfaces from scratches, scuffing, chemicaldamage and premature failure. Polishing agents may also providesecondary attributes such as glossiness, coloration, and depth of imageor clarity. Polishing agents include both polishes and finishes.

Polishing agents of the present invention may be water-based and mayinclude binders, such as polyurethane and/or acrylic resins. Suchproducts preferably provide durability against scuffing, chemicalresistance, and/or adhesion to various substrates.

In water-based polishing systems, freeze thaw stability is important tothe maintenance of the systems performance. Thus, when water-basedpolishing agents are incorporated in the system of the presentinvention, surfactants that provide freeze thaw stability but do notinterfere with system performance may be incorporated. Examples of suchproducts include tributoxyethylphosphate, butyl hydroxybutanoate, andpropylene glycol.

To insure adequate surface wetting and surface protection of the airpurifying polishing system, surface wetting materials that lower thesurface tension of the polishing agent and provide a uniform layer overthe flooring material may be used. Functionalized surface wettingmaterials may also be used, which can add a level of surface marringprotection.

Similar to the cleaning systems of the present invention, foamdestroying polysiloxanes that limit excessive foaminess or bubblingoften caused by surfactants may be incorporated into the air purifyingpolishing system of the present invention. Preferably such defoamingagents have long term efficacy without having an adverse interactionwith the surfactants. Furthermore, when incorporating the DF particlesinto a lower viscosity polishing agent, a rheology modifier may be usedto prevent the DF particles from becoming hardened on the bottom of thecontainer.

Solvents may be incorporated into the air purifying polishing system toaid in solubilizing the resins in the system. Examples of solvents usedin connection with the present invention include glycol ethers, such asdipropylene glycol monomethyl ether, propylene glycol butyl ether,tripropylene glycol methyl ether, and/or diethylene glycol ethyl ether.

In one embodiment of the present invention, the polishing agent of theair purifying polishing system includes approximately 40-95 weightpercent water. Further, the polishing agent may include approximately3-53 weight percent binders, or more preferably 20-50 weight percentbinders, such as acrylic and urethane components. The polishing agent ofthe present invention may include approximately 1-9 weight percentsolvent composition, or more preferably 1-5 weight percent solvent.Moreover, the polishing agent may further include approximately 0.1-1weight percent anti-settling agent, such as a modified urea resin,approximately 0.1-1 weight percent flow and leveling agents, such aspolyether modified siloxane, 0.01-0.05 weight percent fluorinatedsurfactant, and/or approximately 0.01-1.0 weight percent foam destroyingpolysiloxanes. The polishing agent may also include approximately 0.1-1weight percent freeze thaw agent, such as a surfactant blend orpropylene glycol. The polishing agent may include approximately 0.1-1.0weight percent rheology modifier, such as a nonionic urethane copolymer,for leveling. Approximately 0.01-0.5 weight percent biocide, such as ablend of benzoisothiazilinone and methylisothiazilinone, may beincorporated into the polishing agent of the present invention for theprevention of microbial attack. Further, approximately 0.1-5 weightpercent of a wax additive, such as polyethylene blend, may be added tothe polishing agent of the present invention to provide marringresistance. The polishing agent may also include 0.01-0.1 weight percentdispersant such as copolymer of pigment affinic groups.

In another embodiment of the present invention, the polishing agent ofthe air purifying polishing system includes approximately 40-75 weightpercent water. Further, the polishing agent may include approximately23-58 weight percent binders, such as acrylic and urethane components.The polishing agent of the present invention may include approximately1-5 weight percent solvent composition, such as glycol ethers. Moreover,the polishing agent may further include approximately 0.1-3 weightpercent freeze thaw agent, such as a modified phospate, approximately0.1-1 weight percent anti-settling agent, such as a modified urea resin,approximately 0.1-1 weight percent flow and leveling agents, such aspolyether modified siloxane, 0.01-0.05 weight percent fluorinatedsurfactant, and/or approximately 0.01-1.0 weight percent defoamer, suchas foam destroying polysiloxanes. The polishing agent may furtherinclude approximately 0.1-1.0 weight percent rheology modifier, such asa nonionic urethane copolymer, for leveling. Approximately 0.01-0.5weight percent biocide, such as a blend of benzoisothiazilinone andmethylisothiazilinone, may be incorporated into the polishing agent ofthe present invention for the prevention of microbial attack. Further,approximately 0.1-4 weight percent of a wax additive, such aspolyethylene blend, may be added to the polishing agent of the presentinvention to provide marring resistance. The polishing agent may alsoinclude 0.01-0.2 weight percent dispersant such as copolymer of pigmentaffinic groups.

In yet a further embodiment of the present invention, the polishingagent of the air purifying polishing system includes approximately 40-75weight percent water. Further, the polishing agent may includeapproximately 20-50 weight percent acrylic copolymer and approximately5-30 weight percent polyurethane dispersion polymer. The polishing agentof the present invention may include approximately 1-5 weight percentsolvent composition, such as glycol ethers. Moreover, the polishingagent may further include approximately 1-7 weight percent mattingpigment, approximately 1-5 weight percent rheology additive, such asbentonite clay, approximately 0.1-1 weight percent flow and levelingagents, such as polyether modified siloxane, approximately 0.01-0.05weight percent fluorinated surfactant, and/or approximately 0.01-1.0weight percent defoamer, such as foam destroying polysiloxanes. Thepolishing agent may include approximately 0.1-1.0 weight percentrheology modifier, such as a nonionic urethane copolymer, for leveling.Approximately 0.01-0.5 weight percent biocide, such as a blend ofbenzoisothiazilinone and methylisothiazilinone, may be incorporated intothe polishing agent of the present invention for the prevention ofmicrobial attack. Further, approximately 1-15 weight percent of acrosslinker, such as a polyisocyanate polymer, may be included forfurther curing. The polishing agent may also include approximately0.01-0.1 weight percent of a dispersant for additional stabilization ofthe of the DF particles in the DF dispersion. In an embodiment of thepresent invention, approximately 0.1-10 weight percent DF dispersion maybe incorporated with the polishing agent to form the air purifyingpolishing system of the present invention. The DF dispersion mayinclude, DFZnO particles, DFTiO₂ particles, or combinations thereof.

Because the carrier agents of the present invention are typicallycleaning agents and/or polishing agents, the coatings of the presentinvention are often primarily used for cleaning or polishing varioussubstrates and surfaces, such as for wood, concrete, laminate, PVC,vinyl, linoleum, and/or natural stone, in addition to the secondarybenefit of providing a VOC reducing coating system.

The coating systems of the present invention preferably reduce volatileorganic compound levels in the air. For example, the coating systempreferably reduces volatile organic compounds, such as ketones, amines,alcohols, and aldehydes that result in poor indoor air quality. Inaddition to reducing volatile organic compounds from the indoor air, thecoating systems of the present also preferably maintain or improvesurface cleaning and/or polishing properties, such as surface sheen,chemical resistance, surface clarity, and cleaner/polish flow andleveling. The reduction of volatile organic compounds in the surroundingair may be activated when the coating system is applied to a surface andencounters either indoor lighting or natural lighting, such as sunlight.

The present invention includes a method of forming an air purifyingcoating system of the present invention. In one embodiment of theinvention, the method includes the steps of providing diatomic frustuleparticles, such as diatomic frustule zinc oxide particles, diatomicfrustule titanium dioxide particles, or combinations thereof, combiningthe diatomic frustule particles with water and a dispersing additive toform a diatomic frustule particle dispersion, providing a carrier agent,and combining the carrier agent and the diatomic frustule particledispersion to form the air purifying coating system of the presentinvention.

In an embodiment of the method present invention, the diatomic frustuleparticles have a particle size of 1-35 microns. Further, the method ofthe present invention may further include the step of milling thediatomic frustule particles to a particle size of 1-35 microns. In anembodiment of the present invention, the method may further includecombining the diatomic frustule particles with an anti-settlingadditive, a rheology additive and/or a defoamer to form the dispersion.In an embodiment of the method of the present invention, the method mayinclude combining 50-75 weight percent water, 20-50 weight percentdiatomic frustule particles, 0.1-5 weight percent anti settle additive,0.1-2 weight percent foam destroying polysiloxanes, and 1-10 weightpercent dispersing additive to form the diatomic frustule particledispersion.

The method of the present invention may include combining 85-99.9 weightpercent carrier agent and 0.1-15 weight percent diatomic frustuleparticle dispersion. In one embodiment of the method of the presentinvention, the carrier agent may be a cleaning agent. Further, themethod may include combining 95-99.9 weight percent cleaning agent with0.1-5 weight percent diatomic frustule particle dispersion. The diatomicfrustule particle dispersion may be a diatomic frustule zinc oxideparticle dispersion, a diatomic frustule titanium dioxide particledispersion, or a combination thereof. In another embodiment of themethod of the present invention, the carrier agent may be a polishingagent. Further, the method may include combining 90-99.9 weight percentpolishing agent with 0.1-10 weight percent diatomic frustule particledispersion.

Having generally described this instant disclosure, a furtherunderstanding can be obtained by reference to certain specific examplesillustrated below which are provided for purposes of illustration onlyand are not intended to be all inclusive or limiting unless otherwisespecified.

Testing & Examples

The preparation, identification, and testing of example compositions ofthis disclosure are further described below. The particular materialsand amounts thereof recited in these examples, as well as otherconditions and details, should not be construed to unduly limit thisinvention.

Nanoparticle functionalized diatomic frustule material was obtained fromDiatomix Incorporated and tested for use in connection with the presentinvention. The material was a cream-colored powder and had a particlesize of approximately 10 microns. When the material was placed intowater, the particle size was measured at approximately 15 microns.Measurements were taken using an Accusizer N3000. The particle sizedistribution was from 1-20 microns on the raw Diatomix DPA52, 10-micronpowder. The material did not stay in solution and instead started toimmediately settle into a very course grainy appearance in solution. Thematerial was then milled to make the pigment more stable and uniform insolution.

A DFTiO₂ particle dispersion was then formed using the Diatomix materialafter milling. The dispersion was created by combining 50-75 weightpercent water with 1-10 weight percent dispersing additive undermoderate agitation in a dissolver. The water and dispersing additivewere mixed for five minutes. A rheology additive in the amount of 0.1-2weight percent was then mixed in at moderate agitation for 10 minutesuntil the rheology additive was thoroughly mixed in the dispersion. Adefoamer was then added to keep foam from generating in the mixingprocess. Approximately 20-50 weight percent of the milled Diatomixmaterial was then sifted into the batch under agitation and thentransferred from the dissolver to an HCP immersion mill. The dispersionwas milled at a speed of 2500-3500 rpms until the effective Hegmanparticle size was greater than 6 or less than 20 microns.

Testing was performed on both an air purifying cleaning system and anair purifying polish system to determine the air purifying capabilitiesof each. Such testing was done by Research Triangle Park Laboratories inRaleigh, N.C.

The first test was directed to an air purifying cleaning system of thepresent invention. A first control sample with cleaning agent and noDFTiO₂ particle dispersion was analyzed and a second active sample withcleaning agent and DFTiO₂ particle dispersion was analyzed forcomparative purposes. The samples were tested for VOC degradation usingASTM D6670 “Standard Practice for Full-Scale Chamber Determination ofVolatile Organic Emissions from Indoor Materials/Products” byintroducing known concentrations of selected VOCs into 27-liter glasschambers. Two T8 LED light fixtures, which were four feet, were placedoutside of the chambers about six inches from the chambers. The lightswere placed next to each other and were operated for the entire testperiod. The samples were applied directly to glass plates (7 inches×14inches) with three coat layers applied and then cured. The weight of thethree coat layers was 0.1 grams determined by weighing the glass platesbefore and after the applications. The samples were then placed intosealable chambers with the coated side towards the lights for 30minutes. The chambers were sealed and allowed to equilibrate prior theintroducing the VOCs. Temperature and relative humidity was monitoredthroughout the test and was measured at 25° C. and 35-45% relativehumidity. At the beginning of each test and prior to introducing VOCsinto the chambers, air samples were collected from the chambers todemonstrate that no VOCs were in the chamber prior to conducting thetest. Known amounts of the formaldehyde (2.5 ppm) and methyl mercaptan(1.0 ppm) were then introduced into the chambers. Chamber air sampleswere then again collected and analyzed at 1 hour, 24-hour, 48-hour, and72-hour time periods for the specific VOCs introduced. Table 1 belowsets forth the results of VOC air sample testing of the control sampleand active sample at the various time periods.

TABLE 1 Formaldehyde Formaldehyde Methyl Mercaptan Methyl Mercaptan TimePoint Control Sample Active Sample Control Sample Active Sample  1 hour2.50 ppmv 2.50 ppmv 1.00 ppmv 1.00 ppmv 24 hour 2.24 ppmv 2.41 ppmv 0.99ppmv 0.64 ppmv 48 hour 2.13 ppmv 1.82 ppmv 0.42 ppmv 0.34 ppmv 72 hour2.36 ppmv 1.65 ppmv 0.37 ppmv 0.24 ppmv

As set forth above in Table 1, the test chamber having the activesample, which includes the air purifying cleaning system of the presentinvention, had approximately 15 percent less formaldehyde VOC andapproximately 19 percent less methyl mercaptan VOC at 48-hours than thecontrol sample having only cleaning agent. Further, the test chamberhaving the active sample, which includes the air purifying cleaningsystem of the present invention, had approximately 30 percent lessformaldehyde VOC and approximately 35 percent less methyl mercaptan VOCat 72-hours than the control sample having only cleaning agent.

The second test was directed to an air purifying polishing system of thepresent invention. A first control sample with polishing agent and noDFTiO₂ particle dispersion was analyzed and a second active sample withpolishing agent and DFTiO₂ particle dispersion was analyzed forcomparative purposes. The samples were tested for VOCs degradation usingASTM D6670 “Standard Practice for Full-Scale Chamber Determination ofVolatile Organic Emissions from Indoor Materials/Products” byintroducing known concentrations of selected VOCs into 27-liter glasschambers. Two T8 LED light fixtures, which were four feet, were placedoutside of the chambers about six inches from the chambers. The lightswere placed next to each other and were operated for the entire testperiod. The samples were applied directly to glass plates (7 inches×14inches) with one coat layer applied and then cured. The weight of theone coat layer was 1.0 gram determined by weighing the glass platesbefore and after the applications. The samples were then placed intosealable chambers with the coated side towards the lights for 30minutes. The chambers were sealed and allowed to equilibrate prior theintroducing the VOCs. Temperature and relative humidity was monitoredthroughout the test and was measured at 25° C. and 35-45% relativehumidity. At the beginning of each test and prior to introducing VOCsinto the chambers, air samples were collected from the chambers todemonstrate that no VOCs were in the chamber prior to conducting thetest. Known amounts of the formaldehyde (5.0 ppm) and methyl mercaptan(2.5 ppm) were then introduced into the chambers. Chamber air sampleswere then again collected and analyzed at 24-hour, 48-hour, and 72-hourtime periods for the specific VOCs introduced. Table 2 below sets forththe results of VOC air sample testing of the control sample and activesample at the various time periods.

TABLE 2 Formaldehyde Formaldehyde Methyl Mercaptan Methyl Mercaptan TimePoint Control Sample Active Sample Control Sample Active Sample Initial5.00 ppmv 5.00 ppmv 2.50 ppmv 2.50 ppmv 24 hour 4.46 ppmv 4.68 ppmv 2.41ppmv 2.24 ppmv 48 hour 4.17 ppmv 3.99 ppmv 2.44 ppmv 1.89 ppmv 72 hour3.77 ppmv 3.30 ppmv 2.32 ppmv 1.45 ppmv

As set forth above in Table 2, the test chamber having the activesample, which includes one of the air purifying polishing systems of thepresent invention, had approximately 4.3 percent less formaldehyde VOCand approximately 22.5 percent less methyl mercaptan VOC at 48-hoursthan the control sample having only polishing agent. Further, the testchamber having the active sample, which includes the air purifyingpolishing system of the present invention, had approximately 12.5percent less formaldehyde VOC and approximately 37.5 percent less methylmercaptan VOC at 72-hours than the control sample having only polishingagent.

In a second polish for another application, testing was similarlyconducted as in the previous example. Results are illustrated in Table3.

TABLE 3 Formaldehyde Formaldehyde Methyl Mercaptan Methyl Mercaptan TimePoint Control Sample Active Sample Control Sample Active Sample Initial50.0 ng 50.0 ng 6.0 ppmv 6.0 ppmv 24 hour 49.3 ng 39.9 ng 6.0 ppmv 4.8ppmv 48 hour 41.2 ng 17.1 ng 5.4 ppmv 2.7 ppmv 72 hour 26.4 ng 12.7 ng2.2 ppmv 1.4 ppmv

The polish example in Table 3 is similar to that of Table 2 but with theadditional increase in the non-volatile content, a fluorinatedsurfactant, and additional wax. From the data, the formaldehydereduction was 19 percent at 24-hours, and took a steep drop to 58percent at 48-hours, and 51 percent more than the control system at72-hours. From the methyl mercaptan data, the result was 20 percent at24-hours, with a steep drop of 50 percent at 48-hours, and finally 37percent more reduction than the control at the 72 hour point.

A final illustration is a 2-component acrylic-urethane polish coatingsystem. Once again, this system demonstrates the reduction of theairborne chemicals. This data is shown in Table 4.

TABLE 4 Formaldehyde Formaldehyde Methyl Mercaptan Methyl Mercaptan TimePoint Control Sample Active Sample Control Sample Active Sample Initial24.0 ppmv 24.0 ppmv 5.0 ppmv 5.0 ppmv 24 hour 21.6 ppmv 21.6 ppmv NDppmv ND ppmv 48 hour 16.0 ppmv 16.0 ppmv 4.7 ppmv 3.5 ppmv 72 hour 15.6ppmv 12.3 ppmv 2.5 ppmv 1.8 ppmv

The data is slightly different in this example as the system cures underslightly different kinetics. The formaldehyde reduction stayed aboutconstant for the first 48 hours, likely the result of the isocyanate tohydroxyl reaction interfering with the reduction. As curing slowed, the72-hour value was 21 percent from the control to the active systemcontaining the DFTiO₂ particles. The methyl mercaptan reduction was 25percent at 48-hours and finally 28 percent greater than the control at72-hours.

While various embodiments and examples of this invention have beendescribed above, these descriptions are given for purposes ofillustration and explanation, and not limitation. Variations, changes,modifications, and departures from the systems and methods disclosedabove may be adopted without departure from the spirit and scope of thisinvention. In fact, after reading the above description, it will beapparent to one skilled in the relevant art(s) how to implement theinvention in alternative embodiments. Thus, the present invention shouldnot be limited by any of the above described exemplary embodiments.

Further, the purpose of the Abstract is to enable the various patentoffices and the public generally, and especially the scientists,engineers, and practitioners in the art who are not familiar with patentor legal terms or phraseology, to determine quickly from a cursoryinspection the nature and essence of the technical disclosure of theapplication. The Abstract is not intended to be limiting as to the scopeof the invention in any way.

Please amend the claims as follows, all without prejudice or disclaimer:1. An air purifying coating system comprising: 70-99.9 weight percentcarrier agent, wherein the carrier agent is a cleaning agent or apolishing agent; and 0.1-30 weight percent diatomic frustule particledispersion combined with the carrier agent, wherein the diatomicfrustule particle dispersion is a diatomic frustule zinc oxidedispersion, a diatomic frustule titanium dioxide dispersion, or acombination thereof.
 2. The air purifying coating system of claim 1,wherein the dispersion is a diatomic frustule zinc oxide dispersion. 3.The air purifying coating system of claim 1 or 2, wherein the carrieragent is a cleaning agent.
 4. The air purifying coating system of claim3, wherein the coating system comprises 95-99.9 weight percent cleaningagent and 0.1-5.0 weight percent diatomic frustule particle dispersion.5. The air purifying coating system of claim 3, wherein the cleaningagent comprises water, acrylic resin, surfactant, and hydrotropes. 6.The air purifying coating system of claim 3, wherein the cleaning agentcomprises: 80-97 weight percent water; 0.5-5 weight percent acrylicresin; 0.1-1 weight percent hydrotrope; 0.1-3 weight percent emulsifier;0.1-1 weight percent freeze thaw agent; 0.1-1 weight percent flowadditive; 0.1-1 weight percent defoamer; 0.1-1 weight percent surfacemodifier; 0.1-1 weight percent anti-settle additive; and 0.1-0.5 weightpercent biocide.
 7. The air purifying coating system of claim 6, whereinthe acrylic resin comprises alkali-soluble metal-complexed acryliccopolymer, the hydrotrope comprises sodium cumene sulfonate, theemulsifier comprises alkyl polyethylene glycol ether made from aC10-Guerbet Alcohol and ethylene oxide, the freeze thaw agent comprisesa surfactant blend, the flow additive comprises polyether modifiedsiloxane, the defoamer comprises polysiloxanes, the surface modifiercomprises polyether modified siloxane, the anti-settle additivecomprises a modified urea resin; and/or the biocide comprises a blend ofbenzoisothiazilinone and methylisothiazilinone.
 8. The air purifyingcoating system of claim 6, wherein the acrylic resin comprisesalkali-soluble metal-complexed acrylic copolymer, the hydrotropecomprises sodium cumene sulfonate, the emulsifier comprises ethoxylatedfatty alcohols, the freeze thaw agent comprises butyl hydroxybutanoate,the flow additive comprises polyether modified siloxane, the defoamercomprises polysiloxanes, the surface modifier comprises polyethermodified siloxane, the anti-settle additive comprises a modified urearesin; and/or the biocide comprises a blend of benzoisothiazilinone andmethylisothiazilinone.
 9. The air purifying coating system of claim 1 or2, wherein the carrier agent is a polishing agent.
 10. The air purifyingcoating system of claim 9, wherein the coating system comprises90.0-99.9 weight percent polishing agent and 0.1-10.0 weight percentdiatomic frustule particle dispersion.
 11. The air purifying coatingsystem of claim 9, wherein the polishing agent comprises water, binder,freeze thaw agent, and a surface modifier.
 12. The air purifying coatingsystem of claim 11, wherein the binder comprises at least one of acrylicresin and polyurethane resin.
 13. The air purifying coating system ofclaim 9, wherein the polishing agent comprises: 45-95 weight percentwater; 3-53 weight percent acrylic copolymer and polyurethane resin; 1-5weight percent solvent; 0.1-1 weight percent freeze thaw agent; 0.1-1weight percent anti-settling additive; 0.1-1 weight percent flowadditive; 0.01-1 weight percent defoamer; 0.1-4 weight percent waxadditive; 0.01-0.5 weight percent biocide; and 0.01-0.1 weight percentdispersant.
 14. The air purifying coating system of claim 13, whereinthe solvent comprises glycol ethers, the freeze thaw agent comprises asurfactant blend, the anti-settling additive comprise a modified urearesin, the flow additive comprises polyether modified siloxane, thedefoamer comprises polysiloxanes, the wax additive comprisespolyethylene blend, the biocide comprises benzoisothiazilinone andmethylisothiazilinone, and/or the dispersant comprises a copolymer ofpigment affinic groups.
 15. The air purifying coating system of claim13, wherein the solvent comprises glycol ethers, the freeze thaw agentcomprises propylene glycol, the anti-settling additive comprise amodified urea resin, the flow additive comprises polyether modifiedsiloxane, the defoamer comprises polysiloxanes, the wax additivecomprises polyethylene blend, the biocide comprises benzoisothiazilinoneand methylisothiazilinone, and/or the dispersant comprises a copolymerof pigment affinic groups.
 16. The air purifying coating system of claim9, wherein the polishing agent comprises: 40-75 weight percent water;23-58 weight percent acrylic copolymers; 1-5 weight percent solvent;0.1-3 weight percent freeze thaw agent; 0.1-1 weight percentanti-settling additive; 0.1-1 weight percent flow additive; 0.1-4 weightpercent wax additive; 0.01-0.05 weight percent fluorinated surfactant;0.01-1 weight percent defoamer; 0.01-0.5 weight percent biocide; and0.01-0.2 weight percent dispersant.
 17. The air purifying coating systemof claim 16, wherein the solvent comprises glycol ethers, the freezethaw agent comprises a modified phosphate, the anti-settling additivecomprise a modified urea resin, the flow additive comprises polyethermodified siloxane, the wax additive comprises polyethylene blend, thedefoamer comprises polysiloxanes, the biocide comprisesbenzoisothiazilinone and methylisothiazilinone, and/or the dispersantcomprises a copolymer of pigment affinic groups.
 18. The air purifyingcoating system of claim 9, wherein the polishing agent comprises: 40-75weight percent water; 20-50 weight percent acrylic copolymer; 5-30weight percent of polyurethane dispersion polymer; 1-5 weight percentsolvent; 1-7 weight percent matting pigment; 1-5 weight percent rheologyadditive; 0.1-1 weight percent flow additive; 0.01-1 weight percentdefoamer; 0.01-0.5 weight percent biocide; and 1-15 weight percentcrosslinker.
 19. The air purifying coating system of claim 18, whereinthe solvent comprises glycol ethers, the rheology additive comprisesbentonite clay, the flow additive comprises polyether modified siloxane,the defoamer comprises polysiloxanes, the biocide comprisesbenzoisothiazilinone and methylisothiazilinone, and/or the crosslinkercomprises a polyisocyanate polymer.
 20. The air purifying coating systemof claim 2, wherein the diatomic frustule zinc oxide particle dispersioncomprises diatomic frustule zinc oxide particles having a particledispersion comprises diatomic frustule zinc oxide particles having aparticle size of 1-35 microns.
 21. The air purifying coating system ofclaim 2, wherein the diatomic frustule zinc oxide particle dispersioncomprises water, diatomic frustule zinc oxide particles, dispersionadditive, rheology additive, and a defoamer.
 22. The air purifyingcoating system of claim 21, wherein the diatomic frustule zinc oxideparticle dispersion comprises 50-75 weight percent water, 20-50 weightpercent diatomic frustule zinc oxide particles, 1-10 weight percentdispersion additive, and 0.1-2 weight percent rheology additive.
 23. Theair purifying coating system of claim 1, wherein the dispersioncomprises a combination of diatomic frustule zinc oxide particles anddiatomic frustule titanium dioxide particles.
 24. A method ofmanufacturing an air purifying coating system comprising the steps of:providing diatomic frustule particles, wherein the diatomic frustuleparticles are diatomic frustule zinc oxide particles, diatomic frustuletitanium dioxide particles, or a combination thereof; combining thediatomic frustule particles with water, an anti-settling additive, foamdestroying polysiloxanes and a dispersing additive to form a diatomicfrustule particle dispersion; providing a carrier agent, wherein thecarrier agent is a cleaning agent or a polishing agent; and combiningthe carrier agent and the diatomic frustule particle dispersion to formthe air purifying coating system.
 25. The method of claim 24 wherein thediatomic frustule particles are diatomic frustule zinc oxide particles.26. The method of claim 25 wherein the diatomic frustule particles havea particle size of 1-35 microns.
 27. The method of claim 25 furthercomprising the step of milling the diatomic frustule particles to aparticle size of 1-35 microns.
 28. The method of claim 25, wherein thestep of combining carrier agent and the diatomic frustule particledispersion includes 70-99.9 weight percent carrier agent and 0.1-30weight percent diatomic frustule particle dispersion.
 29. The method ofclaim 25, wherein the carrier agent is a cleaning agent.
 30. The methodof claim 29, wherein the step of combining carrier agent and thediatomic frustule particle dispersion includes 95-99.9 weight percentcleaning agent and 0.1-5 weight percent diatomic frustule particledispersion.
 31. The method of claim 25, wherein the carrier agent is apolishing agent.
 32. The method of claim 31, wherein the step ofcombining carrier agent and the diatomic frustule particle dispersionincludes 70-99.9 weight percent polishing agent and 0.1-30 weightpercent diatomic frustule particle dispersion.
 33. The method of claim25, wherein the step of combining the diatomic frustule particles withwater, an anti-settling additive, foam destroying polysiloxanes and adispersing additive includes 50-75 weight percent water, 20-50 weightpercent diatomic frustule particles, 0.1-5 weight percent anti-settlingadditive, 0.1-2 weight percent foam destroying polysiloxane additive,and 1-10 weight percent dispersing additive.
 34. The method of claim 24,wherein the diatomic frustule particles are a combination of diatomicfrustule zinc oxide particles and diatomic frustule titanium oxideparticles.